HighLine spray gun User manual

SPRAY GUN OPERATIONS
MANUAL

HighLine Spray Gun
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Table of Contents
Page
Safety and Handling 2
Important Safety Information 3
Characteristics 5
Technical Specifications 5
General Description 6
Installation and Start-Up 8
Shutdown Procedures 10
Loss of Air Pressure/Emergency Shut-Off 11
Maintenance 12
Mixing Chamber Maintenance or Replacement 13
Screen Screw and Component Maintenance 15
Gun Block Removal 17
Gun Block Reversal 19
Trigger and Trigger Valve Maintenance 21
Air Cylinder Maintenance 23
Troubleshooting Guide 25
Gun Operation 27

HighLine Spray Gun
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Safety and Handling
This chapter contains important information on the safety, handling, and use of
your HighLine spray gun.
Before installing the spray gun and start-up, carefully read all the
technical and safety documentation included in this manual. Pay
special attention to the information to know and understand the
operation and conditions of use of the unit. All of the information
is aimed at enhancing user safety and avoiding possible
breakdowns derived from the incorrect use of the gun.
presents information to alert of a situation that might cause
serious injuries if the instructions are not followed.
presents information that indicates how to avoid damage to the
spray gun, or how to avoid a situation that could cause minor
injuries.
is relevant information of a procedure being carried out.
Careful study of this manual will enable the operator to know the characteristics of
the spray gun and the operating procedures. By following the instructions and
recommendations contained, you will reduce the potential risk of accidents in the
installation, use, or maintenance of the spray gun. You will provide a better
opportunity for incident-free operations for a longer time, greater output, and the
possibility of detecting and resolving problems fast and simply.
Keep this operations manual handy for future reference to useful information. If you
lose the manual, contact ArmorThane for a new copy.

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Important Safety Information
The HighLine spray gun has been designed and built for the application of
polyurethane and polyurea chemical systems, and polyurethane foam chemical
systems.
The design and configuration of the HighLine spray gun does not
allow its use in potentially explosive atmospheres or exceeding
the pressure and temperature limits described in the technical
specification of this manual to be exceeded.
Always use liquids and solvents that are compatible with the spray gun. If in doubt,
contact the ArmorThane Technical Department.
When working with the spray gun, it is recommended that the operator wear
suitable clothing and personal protection, including, without limitation, gloves,
protective goggles, safety footwear, and face masks. Use breathing equipment
when working with the spray gun in enclosed areas or in areas with insufficient
ventilation. The introduction and follow up of safety measures must not be limited
to those described in this manual. Before beginning to work with the spray gun, a
comprehensive analysis must be made of the risks derived from the products to be
dispensed, the type of application and the working environment.
To prevent possible injury caused by incorrect handling of
the materials and solvents used in the process, carefully read
the Material Safety Data Sheets (MSDS) provided by
ArmorThane.
Deal with the waste according to current regulations.
To avoid damage caused by the impact of pressurized fluids,
do not open any connection or perform maintenance work on
components subject to pressure until the pressure has been
completely eliminated.
Use suitable protection when operating, maintaining, or being
present in the area where the equipment is functioning. This
includes, but is not limited to, the use of protective goggles,
gloves, shoes, and safety clothing and breathing equipment.

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The equipment includes components that reach high
temperatures and can cause burns. Hot parts of the
equipment must not be handled or touched until they are
completely cool.
To prevent serious injury through crushing or amputation, do
not work with the equipment without the safety guards
installed on the moving parts. Ensure that all the safety
guards are correctly reinstalled at the end of the repair or
maintenance work of the equipment.

HighLine Spray Gun
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Characteristics
Internal mixing from high pressure impingement
Automatic cleaning with air pressure
No solvents required
Exterior lubrication of the mix chamber
Weight: 2.8 lbs
Dimensions: 7” x 4” x 8” (L x W x H)
Technical Specifications
Maximum Working Pressure:
3500 psi
Maximum Air Pressure:
125 psi
Maximum Output (1:1 ratio):
40 lb/min
Minimum Output (1:1 ratio):
3.3 lb/min
Opening Force @ 110 psi:
200 lb
Closing Force @ 110 psi:
205 lb
Approximate Air Consumption @ 110 psi:
10 cfm

HighLine Spray Gun
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General Description
For better knowledge of the HighLine spray gun, the main components and their
description are shown. For a more precise identification, see the parts identification
section.
1. Gun Block
6. Coupling Block Gasket
2. Coupling Block
7. Coupling Block Mounting Screw
3. Mixing Chamber & Seal
8. Grease Fitting
3a. Air Seal
9. Trigger Handle
4. Air Cap
10. Gun Handle with screws
5. Manual Valve
11. Air Cylinder with screw and nut

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13. Iso (A) Screen Screw
20. Side Seal
13a. Resin (B) Screen Screw (not shown)
21. Cleanout Plug
14. Screen
22. Air Safety Slide Valve
15. Screen Screw Seal
23. Pipe Nipple
16. O-Ring
24. Air Cylinder Mtg. Clamp
17. Spring
25. Pipe Plug
18. Check Valve Assembly
26. Piston Shaft (not shown)
19. O-Ring
27. Air Coupling

HighLine Spray Gun
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Installation & Start-Up
When working with the HighLine spray gun, or performing
maintenance work, wear suitable safety protection in accordance
with the recommendations and specifications provided by
ArmorThane.
1. Ensure the coupling block manual valves (5) are closed by turning them to the
full clockwise position.
Excessive force closing or opening the manual valves may result
in damage to the manual valves and/or coupling block.
2. CLOSE the air safety slide valve (22) (downward/rearward position)
3. Connect the spray gun to the coupling block using the supplied hex key wrench.
Ensure coupling block gaskets (6) are in place.
4. Connect the air supply to the air safety slide valve.
The material delivery hoses are color-coded red and blue,
allowing the user to recognize them. The red corresponds to
the isocyanate (A) and the blue to the resin (B). To avoid
connection errors, the coupling connections of the
isocyanate (A) and resin (B) hoses are also different sizes,
which makes it difficult to swap connections.

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5. OPEN the air safety slide valve and ensure there are no air leaks.
6. Pull the trigger (9) several times to check for correct movement of the mixing
chamber (3).
7. Ensure the material pressures at the proportioner and the material temperature
in the material heaters and heated hoses are as recommended by ArmorThane
(see machine operations manual).
8. OPEN each manual valve by turning to the full counter clockwise position (six ½
turns).
9. Perform a test spray.
The HighLine spray gun is designed with the flexibility to have the air input at the
base of the gun handle (11) (standard configuration), or in the rear.
To make the change, do the following:
1. Disconnect the pipe nipple (23) with air coupling (27) from the bottom of the
gun handle.
2. Unscrew the first pipe plug (25) at the rear of the gun and reinstall into the
bottom of the gun handle where pipe nipple was removed.
3. Remove safety slide valve (22) from the pipe nipple and reinstall it to the
rear of the gun handle.
4. Use Teflon tape or sealing paste on all threads to prevent air leaks.

HighLine Spray Gun
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Shutdown Procedures
1. CLOSE the manual valves (5) by turning them to the full clockwise position.
Excessive force closing or opening manual valves may result in
damage to the manual valves and/or coupling block.
2. Lubricate the mixing chamber through the fitting (8) until a fine mist of grease is
sprayed from the gun with the grease and grease gun supplied in the tool kit.
This action will minimize moisture in the cleaning air of the gun from reacting
with the isocyanate product and prevent crystallization, which may damage the
internal parts.
3. CLOSE the safety slide valve (22)
4. Disconnect the air supply.
The injection of grease supplied with the gun at the end of the
day will minimize maintenance time and eliminate the need to
remove the mixing chamber each day to clean it. Use of
grease with high moisture content will not achieve the
desired results.

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Loss of Air Pressure/Emergency Shut-Off
1. Using supplied 5/16” nut driver, push IN on exposed end of piston shaft (26).
2. CLOSE each material supply valve (5).
Excessive force closing or opening manual valves may result in
damage to the manual valves and/or coupling block.

HighLine Spray Gun
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Maintenance
To obtain maximum performance from your HighLine spray gun, it is necessary to
periodically perform certain maintenance operations.
Before proceeding with any maintenance work on the HighLine
spray gun, make sure the air safety slide valve (22) and the
manual valves (5) are CLOSED. Trigger the spray gun to remove
internal material pressure. It is recommended to remove the
spray gun from the coupling block.
To prevent possible injury caused by incorrect handling of the
raw materials and solvents used in the process, carefully read
the Material Safety Data Sheet (MSDS) provided by
ArmorThane.
Deal with the waste according to current regulations.
To prevent serious damage caused by the impact of
pressurized fluids, never open a connection or perform
maintenance work on components subject to pressure until all
pressure has been eliminated.
Use suitable protection when operating, maintaining, or being
present in the area where the equipment is functioning. This
includes, but is not limited to, the use of protective goggles,
gloves, shoes and safety clothing, and breathing equipment.
The equipment includes components that reach high
temperatures and can cause burns. Hot parts of the equipment
must not be handled or touched until they have cooled
completely.
To prevent serious injury through crushing or amputation, do
not work with the equipment without the safety guards
installed on the moving parts. Ensure that all the safety guards
are correctly reinstalled at the end of the repair or maintenance
work of the equipment.

HighLine Spray Gun
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Mixing Chamber Maintenance or Replacement
1. CLOSE the manual valves (5) by turning them to the full clockwise position.
Excessive force opening or closing manual valves may result in
damage to the manual valves and/or coupling block.
2. Trigger the spray gun over a waste container to release internal material
pressure.
3. CLOSE the air safety slide valve (22).
4. Remove the air cap (4)
5. Loosen or remove both screen screws (13) to ensure no damage to side seal
(20) faces (not shown), when the mixing chamber (3) is removed.
6. Use a 5/16” nut driver and unscrew the piston shaft (26) (not shown) from the
mixing chamber.
7. Remove the mixing chamber and air seal (3A) from the front of the spray gun.
8. Flush spray gun to remove any residue.

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9. Clean or replace the mixing chamber, including air seal, as required.
10.Reassemble the mixing chamber in reverse order.
A small amount of grease applied to the mix chamber and side
seals upon assembly is recommended.
Use wooden or plastic tools or a brass brush for cleaning. Do not
use metal or abrasive tools that can scratch the contact surfaces.

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Screen Screw and Component Maintenance
To avoid possible contamination by the residual chemical inside the
spray gun, do not interchange the isocyanate (A) parts with the resin
(B) parts. The isocyanate (A) side is identified with a groove around
the screen screw head.
1. CLOSE the manual valves (5) by turning them to the full clockwise position.
Excessive force opening or closing the manual valves may result
in damage to the manual valves and/or coupling block.
2. Trigger the spray gun over a waste container to release internal material
pressure.
3. CLOSE the air safety slide valve (22).
4. Use a 15/16” open-end wrench and remove the screen screw (13).
5. Clean or replace the screen (14) as required.

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6. Remove the side seal (20), spring (17), and check valve (18) from the screen
screw. If necessary, unscrew the access plug (21) to remove the components.
Inspect the components gasket (15) and O-Rings (16, 19). Clean or replace as
required.
7. Apply lubrication to the O-Rings and threads, and reassemble in reverse order.
8. The spray gun is now ready for service.
When replacing O-Rings, replace ALL O-Rings included in the
appropriate kit.

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Gun Block Removal
1. CLOSE the manual valves (5) by turning them to the full clockwise position.
Excessive force in opening or closing the manual valves may
result in damage to the manual valves and/or coupling block.
2. Trigger the spray gun over a waste container to release internal material
pressure.
3. CLOSE the air safety slide valve (22).
4. Remove the spray gun from coupling block (2).
5. Remove the mixing chamber (3) as direction on page 13
6. Use a 1-3/8” open-end wrench and loosen the gun block retainer nut (12).
7. Carefully pull the gun block (1) forward to remove.
8. Service the gun block and component parts as required.
9. Reassemble in reverse order.

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The mixing chamber must be removed and installed through the
front of the gun block before removal and reinstalled AFTER the
gun block is reinstalled.
Use wooden or plastic tools or a brash brush for cleaning. Do not
use metal or abrasive tools that can scratch the contact surfaces.

HighLine Spray Gun
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Gun Block Reversal
1. CLOSE the manual valves (5) by turning them to the full clockwise position.
Excessive force opening or closing the manual valves may result
in damage to the manual valves and/or coupling block.
2. Trigger the spray gun over a waste container to release internal material
pressure.
3. CLOSE the air safety slide valve (21).
4. Remove the mixing chamber (3) as directed on page 13.
5. Use a 1-3/8” open-end wrench and loosen the gun block retainer nut (12).
6. Pull the gun block (1) forward approximately ¼” (6.35 mm) to free from the
retaining pin (not shown).
7. Rotate the gun block 180 degrees and reseat rearward, being careful to re-
engage the retaining pin.
8. Tighten the gun block retainer nut.